SAAB WIS ONLINE

Inner sill, complete

Inner sill, complete

Certain weld joints on the car may be MIG brazed whereby the filler material is bronze rod. The characteristic sign of MIG brazing is that the joint is gold coloured. MIG brazing must always be replaced with new MIG brazing.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


To remove

Important

Body reinforcement must only be cut and joined if it is specifically covered in the method description. Unless otherwise stated, it is mandatory to discard and renew the damaged reinforcement component.



1. Position the car in an aligning bench and cross-measure if necessary.

2. Cut the front joint 55mm above the measuring point.


3. Cut the half sill's outer panel roughly at the B-pillar.

4. Cut the rear wing as illustrated.


5. Drill out the spot welds beneath the entire sill.


6. Drill out the spot welds on the sill joint at the back door.


7. Drill out the spot welds on the rear wing.


8. Drill out the spot welds on the upper part of the rear sill, as well as the door opening.


9. Drill out the spot welds on the upper part of the front sill, as well as the door opening.


10. Bend out the lower part of the sill panel.


11. Drill out the spot welds in the B-pillar reinforcement.

12. Cut the B-pillar complete at the upper measurement point.

13. Knock loose the outer sill, B-pillar and part of the rear wing.

14. Drill out the spot welds and grind off the welds for the inner B-pillar reinforcement. Note that the seam welds may be MIG brazed.


15. Knock loose the reinforcement.

16. Cut the outer panel 40mm from the joint in the remaining section. Drill out the spot welds and knock away the panel. Do not damage the panel underneath.

17. Drill out the spot welds on the rear sill reinforcement.


18. Knock away the reinforcement.

19. Drill out the spot welds on the front sill reinforcement.


20. Grind down the seam welds. Note that the welds may be MIG brazed.

21. Drill out the spot welds on the rear sill reinforcement.


22. Grind down the seam welds. Note that the welds may be MIG brazed.

23. Knock loose the sill reinforcement.

24. Drill out the spot welds on the inner reinforcement and in the wheel housing.


25. Grind down the seam welds. Note that the welds may be MIG brazed.

26. Knock loose the inner reinforcement.

27. Drill out the spot welds on the inside.


28. Grind down the seam welds. Note that the welds may be MIG brazed.


29. Remove the rear screw.

30. Drill out all spot welds along the inner sill.

31. Knock loose the inner sill.

32. Align any deformed plates.


To fit



1. Drill holes for the plug weld on the spare part inner sill.

2. Grind clean the surfaces on the body and the spare part that are to be spot and plug welded.

3. Apply welding primer on the surfaces to be plug and spot-welded. Use Teroson Zink spray.

4. Adjust and secure the inner sill with several welding clamps.

5. Fit the screw at the rear edge.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.



6. Spot and plug weld, and seam weld the inner sill into position. Replace any MIG brazing.


7. Grind the welds. Apply anti-corrosion agent to internal surfaces. Use Terotex HV 400.

8. Grind clean the surfaces on the inner reinforcement and the body that are to be spot and plug welded.

9. Apply welding primer to the locations to be welded.

10. Adjust the inner reinforcement and secure using welding clamps.

11. Spot and plug weld the inner reinforcement.


Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


12. Seam weld the inner reinforcement into position. Replace any MIG brazing.

13. Grind the welds. Apply anti-corrosion agent to internal surfaces.

14. Grind clean the surfaces on the reinforcement, the spare part and the body that are to be spot and plug welded.

15. Apply welding primer to the locations to be welded.

16. Adjust the reinforcement and secure using welding clamps.

17. Spot and plug weld on the reinforcement.



Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


18. Seam weld the reinforcement. Replace any MIG brazing.

19. Grind the welds.

20. Grind the surfaces on the rear reinforcement that are to be spot and plug welded.

21. Apply welding primer to the locations to be welded

22. Adjust the rear reinforcement.

23. Spot and plug weld the rear reinforcement.


24. Grind the welds. Apply anti-corrosion agent to internal surfaces.

25. Cut the B-pillar reinforcement roughly so that it overlaps the joint by three centimetres.

26. Align the reinforcement and secure it with several welding clamps in the lower reinforcement.

27. Cut the reinforcement and the existing reinforcement on the body together so that the joint can be butt welded.

28. Drill 4 holes in the lower section for plug welding.

29. Grind away the primer and apply welding primer to the surfaces to be plug welded.

30. Align the reinforcement against the lower reinforcement and secure it with several welding clamps.

31. Plug weld the bottom edge of the reinforcement.


32. All-weld the joint.

33. Grind the welds so that the outer panel fits over the reinforcement.

34. Cut the front door frame so that it matches the previous cuts.

35. Drill holes in the lower edge and the rear door frame joint for plug welding.

36. Grind away the primer on the surfaces to be welded.

37. Apply welding primer to the locations to be welded.

38. Align the outer panel and secure it with several welding clamps.

39. Seam weld the upper joint and the joint in the front door frame.


40. Plug weld the lower part towards the sill.

41. Grind away the primer on the surfaces of the inner reinforcement to be welded.

42. Apply welding primer to the locations to be welded.

43. Align the reinforcements and secure them with several welding clamps.

Warning

Repairs to MIG brazing using conventional welding methods and normal filler material are forbidden. Cracks can arise which can impair performance in a collision.


44. Spot weld the entire B-pillar reinforcement, inner reinforcements and the sill. Replace MIG brazing or the seam welds.


45. Smooth off the welds.

46. Cut the new side panel roughly so that it overlaps the joint by about centimetres.

47. Adjust the side panel on the body and cut the existing panel at the same time so that the joint can be butt welded.

48. Drill holes for plug welding at the bottom of the side panel.

Grind the surfaces to be welded.


49. Apply welding primer to the surfaces to be spot and plug welded.

50. Align the side panel and secure it with several welding clamps.

Spot and plug weld the side panel.

51. All-weld the joint.

52. Smooth off the welds.

53. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.

54. Apply primer to all bare metal surfaces.

55. Seal joints and seams with sealant.

56. Apply anti-corrosion agent after painting. Use Terotex HV 400.